Resinous esters of acrylic acid and methacrylic acid



Gil -J Patented June 8, 1954 UNITED STATES ?ATENT OFFICE RESINOUS ESTERS OF ACRYLIC ACID AND METHACRYLIC ACID Virginia W. Fegley and Stanley P. Rowland, Philadelphia, Pa., assignors to Rohm & Haas Company, Philadelphia, Pa., a corporation of Delaware No Drawing. Application July 9, 1952, Serial No. 298,008

18 Claims. 1 This invention relates to polymerizable esters of acrylic and methacryllc acid and to the polymers and copolymers thereof. It relates to esters which are readily polymerized to linear, thermoplastic resins which resins in turn are convertible to cross-linked resins by the application of heat.

The monomeric esters of this invention have the general formula in which R represents a hydrogen atom or a methyl group and R and R each represents a hydrogen atom or a hydrocarbon radical, preferably an alkyl group. These esters polymerize very readily to form linear, thermoplastic polymers which have the following general formula in which R, R and R are identical with the same characters described above:

The linear, thermoplastic polymers in turn are heat-convertih'le' -and can be changed into crosslinked polymers which for practical purposes have the properties of. thermoset resins. This is possible because the cyclic portions of the molecules-the dioxolane groups-can be made to open under the effect of heat and/or a catalyst and to provide cross-linkages according to The monomeric products of this invention are preferably made from an ester of acrylic acid or methacrylic acid and a 4-hydroxymethyldioxolane according to the following general reaction by transesterification or ester-interchange: 1

In the above equation R represents a hydrocarcarbon group, preferably an alkyl group of one to four carbon atoms. The group represented by R can be a hydrocarbon group of higher molecular Weights; e. g., a phenyl or a cyclohexyl or an amyl group, but the processes employing such esters of methacrylic acid are less efficient and costlier. What is actually recommended is the use ofmethyl or ethyl methacrylate.

The other reactant, a -hydroxymethyldioxolane, having the formula is readily prepared in gOOd yields by the reaction of an aldehyde or ketone with glycerol (J. Am. Chem. Soc. 6'7, p. 1621 (1945); J. Org. Chem. 14%, p. 1103 (1949)). Thus, the dioxolane from glycerol and formaldehyde has the formula HOCHr$H-?E (I-Iere R and R are hydrogen atoms.) The products from other aldehydes, R CI-IO, such as acetaldehyde, butyraldehyde, or 'benzaldehyde have the formula.

HOOHrCHCH2 t H/ m wherein R is a hydrocarbon radical such as the methyl, propyl, or phenyl radical of the aldehyde. When ketones, R -CO-.-R such as acetone,

I methylethyl ketone, methyl cyclohexyl ketone,

or acetophenone, are used, the dioxolanes have the general formula HOCHz-CH(3H2 t t 0 R1 \R2 wherein R and R are the same hydrocarbon groups as were present in the ketone. All of these reactants are e-hydroxymethyldioxolanes which differ in structure one from the other only as regards the R and R substituents on the carbon atom at position 2. Of these, 2,2-dimethyl- 4-hydroxymethyldioxolane is the compound of first choice because the resins made therefrom are particularly hard and have high heat-distortion temperatures. Keeping the end-products in mind, it is recommended that the total number of carbon atoms in the groups which are represented by R and R be twelve or less. Thus, for example, when R is a hydrogen atom, R can be any hydrocarbon group, free of nonbenzenoid or aliphatic unsaturation, up to the dodecyl group; or when R is a butyl group, R can contain up to eight carbon atoms, as in the phenyl, tolyl, or octyl groups.

The transesterification reaction shown above is carried out at elevated temperatures, preferably at a pot-temperature from about 70 C. to the boiling point of the reaction mixture, so that the alcohol, R OH, which is formed can be removed by distillation as the reaction progresses. In this way the reaction proceeds rapidly to sub stantial completion. Temperatures below the boiling point of the reaction mixture can be used, but the reaction reaches equilibrium, and the yield is consequently lower, if the alcohol, P. OI-I, is not removed as it is formed. The use of alkali metal alkoxides as activators and accelerators in the transesterification reaction is recommended. Sodium methylate and ethylate are particularly recommended. Reduced pressures can also be employed.

While the ester of acrylic or methacrylic acid and the l-hydroxymethyldioxolane react in equiincluding di-beta-naphthol, hydroquinone, tertbutyl catechol, pyrogallol and the like.

Alternatively, the products of this invention can be made by the direct esterification of acrylic acid, methacrylic acid, or the anhydrides thereof with a 4-hydroxymethyldioxolane.

The monomeric esters of this invention polymerize at temperatures as low as 0 0., and in the neighborhood of 200 C. they polymerize rapidly even though they may contain customary amounts of inhibitor. Polymerization is accelerated by the use of free-radical catalysts such as the following in amounts from 0.01% to 5%, and preferably from'0.02% to 2%. based on the weight of the polymerizable compounds: Benzoyl peroxide, acetyl peroxide, lauroyl peroxide, tert.-butyl hydroperoxide, di-tert.-butyl peroxide, tert.-butyl perbenzoate, stearoyl peroxide, ascaridol, cumene hydroperoxide, per-salts such as ammonium persulfate, and the like. The polymers can also be made under the influence of ultra-violet light and a catalyst such as benzoin.

Polymerization can take place in bulk, in solution, in suspension, or in emulsion. Consequent ly, the thermoplastic polymers can be obtained in the form of sheets, blocks, rods, slabs, powders, pellets, or beads, all of which can be molded into a variety of shapes and forms by conventional molding techniques. Furthermore, the solutions and emulsions of the polymers are very useful as surface coatings for metal, leather, wood and the like as well as for the treatment of fabrics. After their application the films of resin can be cross-linked and insolubilized by a heat-treatment.

The monomeric esters of this invention are also copolymerizable with other compounds which contain at least one vinylidene group,; CI-Iz=C And when they are thus copolymerized, they impart to the resultant copolymers the ability to change under the influence of heat to cross-linked resins having enhanced resistance to chemicals and solvents. Compounds which can thus be copolymerized are exemplified by the following: Acrylic and methacrylic esters such as methyl methacrylate, ethyl acrylate, octyl acrylates, and benzyl acrylate; vinyl esters such as vinyl acetate and propionate; vinyl chloride; vinylidene chloride; acrylonitrile; allyl esters such as diallyl phthalate and diallyl sucoinate; vinyl hydrocarbons such as styrene, divinylbenzene, and vinylnaphthalene; and maleic anhydride. copolymers containing mixtures of two or more of the compounds containing the Vinylidene group CH2=C are also embraced by the invention. The above list is by no means exhaustive and reference is made to U. S. Patent No. 2,578,861 wherein are listed a great number of compounds containing the group CH2=C which can be copolymerized with the products of this invention either individually or as mixtures of two or more.

To date, the most useful copolymers are those which include either maleic anhydride or an alkyl ester of acrylic or methacrylic acid containing one to eighteen carbon atoms in the alkyl group. The maleic anhydride copolymers are particularly valuable because they react with azolines according to the process of U. S. Patent No. 2,543,602 to form linear, polymeric imidoesters which can be subsequently cross-linked by treatment with heat and a catalyst. Th esters of acrylic and methacrylic acids mentioned above constitute a preferred class of materials which are eopolymerizable with the esters of this invention. This is because the resultant copolymers are colorless and can be used in the form of solutions as surface-coatings, in the form of molding powders for the production of molded articles and in the form of sheets for the manufacture of signs and aircraft enclosures. All of the finished articles from the copolymers can be cross-linked and, accordingly, they have real advantages over the linear polymers of the same acrylic or methacrylic esters alone.

Because the simple alkyl esters of acrylic and methacrylic acid are copolymerizahle with the dioxolone esters of this invention, it is evident 6 eight grams of the cataylst mixture was added in three portions over a period of 13 hours, at which point the calculated amount of binary distillate was removed and collected. The excess methyl methaorylate was then removed by distillation at reduced pressures. The isopropylideneglyceryl found desirable to have at least and prefmethacrylate, erably on a molar basis, of the dioxolane ester so that there are present a sufficient num- E I I ber of the dioxolane units to bring about eiTec- 10 a tive cross-linking. Copolymers containing from 10% to 90% of the new esters of this invention and 90% to 10% of a copolymerizable compound c Q zfigg gfi fi propertles and are embraced by and represented a 90.3% yield. This product was It is also within the s ope of thisinvention to distilled and the lowing properties were deinclude dyes, pigments, release agents, extenders, termmed' fillers, and the like in the polymerization of the 1-442 new-monomers. In this way, colored and transdEO Z 111924 parent, or colored and translucent, or colored apo ficati nu ber: 8 alfiulated 2 and opaque products can be made which enjoy Solubility: Soluble in acetone, butyl acetate, the same advantages as the crystal-clear mateethylene dichloride,'toluene and dioxane. Inrials. soluble in ethanoland water. The1 thermoplastic, lilijiear polymlersi-bwhile in Example 2 any s ape or. orm, can e crossin e y means of heat and/or by a catalyst of the acidic or h l f ester of Example 1 was Friedebcmfts typa Typical of the suitable merized insolution as follows: 250 parts by weight catalysts are the following: Boron trifluoride the isopropyndene'glycery.l methacrylate was and its complexes with ethers acids, and alcodlssolved m 250 parts bywelght 9 tqluene and hols, ethyl sulfate, alkyl acid phos hates, p- 3 of l peroxide m flask toluenesulfonic acid, titanium tetrachloride, staneqiillpmd W 1th a gas-Hue tube t i nic chloride, and the like. The resultant prodagltator, and reflux condinsert' dmlde ucts are characterized by having far greater rewas bubbled through the Stlrred 501M101} throughsistance to solvents than the original linear polyout the mute betting penod' The mlxture g mers and by having a higher softening point heated to refluxing temperature and held or The advantage of heating the resins in order to th1ee hours Then partsf (1%) 9 g cross-link them is most evident in those cases peroxlfle was added after Whlch .heatmg at t e Where the resins are laid down in the form of refluxmg temperature was .contmued for two films from solutions or emulsions and are then 49 more hours .Another port-Ion of Parts of heated As a result 0f the heating and cross benzoyl peroxide was added at this time and linking the films acquire hardnesslnd a much the heating was continued for an additional.

u period of five hours. By this time 99.4% of the gfig gg i esstance to olgamc solvents and monomer had polymerized toa viscous solution The fon'OWing examples in which all parts are having a viscosity when measured at solids. by Weight, serve to illustrate the preparation and gl pols? f polymerization of the new monomeric esters 18 so u was m e por Ion-o 1 was treated with a 10% solution of boron .trifluo- Example I ride in diethyl ether in such an amount as to .l 1% of the catalyst based on the Wei ht In a one-litei distilling flash, fitted Wlbh a 59 provide packed column and a partial take-off head, was of the polymer, Fllms of the catalyzed placed 132.2 grams (one mole) of isopropyl-' Fe l' solutlons were made flowmg the ideneglycerol or 2,2 dimethyl 4 hydrOXymethy1 solution on glass The filrns were air-dried or dioxolane of the formula baked and the dried films were tested for hardness (on the pencil hardness scale) and for resistance to solvent (by measuring the number I I of strokes before failure with a pad saturated with acetone). Following is a tabulation of the results showing the improvement which results from cross-linking the polymer:

Catalyst Treatment ggg figgg Clarity None Drledlnair 24hours 5B Perfectly Clear. D01 %1 10l1l 2,t 150G H Do. 1% BFa-ether Driedmair 24 hours F 120.; Do. Do %houratl500 2H overl50 Do;

together with 500.5 grams of methyl methacrylate Example 3 (5 moles) and 5 grams of di-beta-naphthol. Fourteen grams of a solution of 2 grams of sodium in .0 grams of methanol was added. The mixture was heated slowlyto a, vapor temperature of 642 C. and a binary distillate of methanoland methyl methacry-late was removed, Twenty- A sheet of polymeric isopropylideneglyceryl methacrylate was cast as follows: The monomeric ester prepared by the process of Example 1 above a flask at 60 C. under reduced pressure until all occluded, extraneous gases were removed. After this degassing operation the liquid was poured into a cell made of two pieces of plate glass (12" x 12" sealed at the edges by flexible spacers. The filled cell was sealed in order to exclude air and was placed in an oven having automatic control of temperature, where it was heated at 60 C. for 16 hours followed by a onehour period of heating at 70 C., 80 C., 90 C., 100 C., and 110 C. At this point polymerization was essentially complete and 'the product obtained was a clear, colorless sheet of polymer which had about the same appearance, hardness and abrasion-resistance of a sheet of polymerized methyl methacrylate but which was insoluble in acetone and toluene whereas a comparable sheet of polymethyl methacrylate dissolved completely.

Example 4 A. A film-forming solution of a copolymer of 30% methyl acrylate and 70% isopropylideneglyceryl methacrylate was madeas follows: Into a three-necked fiask, equipped with thermometer, mechanical stirrer, gas-inlet tube and refiux condenser were charged 700 parts of isopropylideneglyceryl methacrylate as prepared by the process of Example 1 above, 129 parts of methyl acrylate, 829 parts of toluene and 8.3 parts of benzoyl peroxide (1% based on monomeric compounds). Nitrogen was bubbled through the stirred solution throughout the following heating schedule. The solution was heated to 90 C. and held therefor 18 hours.

Portions of benzoyl peroxide (1.6 parts equivn alent to 0.2%) were added at the end of the fifth, sixth, and seventh hours. The product was a crystal-clear solution having a viscosity of 275 poises when diluted to 40% solidscontent with toluene and measured at C.

B. Another film-forming solution in xylene was made in the same way by the polymerization of a mixture of equimolar amounts of styrene and isopropylideneglyceryl methacrylate. The

resultant product had a viscosity of 1.65 poises when measured as a 40% solution in xylene at 25 C.

The character of the films of these two polymers is indicated in the following tabulation where Ex-4A indicates the product described in part A of Example 41 and Ex-4B indicates the product described in part B of Example 4.

I dioxide.

toluene at 25 C. The product obtained by carrying out the copolymerization in xylene had a viscosity of 98 poises when measured as a solution in xylene at 25 C. Both solutions were clear and substantially colorless and both dried to clear, colorless films when air-dried. On being baked, the films increased in their resistance to solventsparticularly to acetone.

Example 6 An emulsion of a copolymer was made in the following manner: Forty parts of ethyl acrylate, 45 parts of isopropylideneglyceryl methacrylate, 45 parts of water, and 83 parts of a 20% aqueous solution of a commercially available emulsifying agent (TRITON 773, sold by Rohm 8; Haas Com-. pany, Philadelphia, Pa. and known to be the sodium salt of alkylphenoxyethyl sulfate) was vigorously stirred and heated under a blanket of carbon As catalyst there was added 0.019 part of ammonium persulfate; and the emulsion was heated for 24 hours at -60 C. A 96.4% conversion of monomers to copolymer resulted. When the resultant emulsion was applied to a surface and was dried, it deposited a clear film which was readily soluble in acetone. Heating of the film for one-half hour at 150 C. greatlyincreased the resistance to acetone.

Example 7 Isopropylideneglyceryl acrylate was prepared by reacting 1.25 moles of acrylic anhydride with 1.0 mole of isopropylideneglycerol, or 2,2-dimethyl-4-hyclroxymethyldioxolane, for a week at room temperature in the presence of 1%, based on the acrylic anhydride, of hydroquinone and 5 moles of pyridine. At the end of this time the upper phase was removed and distilled. The product, whose structure was confirmed by analysis, boiled at '76'77 C./3.0-3.5 mm.

It had a saponification number of 300 (calculated value is 301.5), a refractive index at 20 C.-

of 1.4399, 2. density at 20 C. of 1.068, and was soluble in acetone, butyl acetate, ethylene dichloride, toluene, dioxane and ethanol, but was insoluble in water.

Example 8 A polymer of the product of Example 7 was made by heating 21.5 parts of the material, while dissolved together with 0.11 part of benzoyl peroxide in 10.75 parts of methylisobutyl ketone,

Pencll- Acetone- Copoly'mer Catalyst Treatment Hardness Resistance Err-4A None Drledlnalr24hours..- 4B 8. Ex-4A. 1% BFa-ethe-r do 313 30-35. Ex-4A 1% ptoluene sulfonic do B about90.

- am Err-4A None %hr.atl50 O 2H 20. Ex-4A 1% BFa-ether "do 4H over-150. Err-4A 1% pdtoluene sulionic 2H Do.

an Err-4B None 2H 25. Err-4B 1% BFa-ether 3H 31701115100.

Example 5 at -100 C. The reaction product was further Terpolymers were made from mixtures containing 0.9 mole of ethyl methacrylate, 0.1 mole of isopropylideneglyceryl methacrylate, and 0.25 mole of maleic anhydride by polymerizing the mixture in the presence of 0.55% of benzoyl peroxide at 80 C. over a period of 12 hours by the general method described in Example 4 above. In one case the solvent was toluene and the resinous product attained a viscosity of 14 poises when measured as a solids-content of 40% in 75 diluted to a solids-content of 50% with 10.74 parts of methylisobutyl ketone. Evaporation of a portion of the solution showed that polymerization was complete. The 50% solution was clear and colorless and had a viscosity of 18 poises at 25 C.

A film of the solution was baked at C. for 30 minutes and the resultant dried film was found to be clear, colorless, tack-free, hard, and resistant to organic solvents, v

Example 9 Methyl methacrylate and the product of Example were mixed in equal weights and catalyzed with 0.5% of benzoyl peroxide. After deaeration of the mixture it was placed in a glass cell like that described above in Example 3 and was heated 60 hours at 60 C. and one hour each at 60 C., 70 0., 80 0., 90 0., 100 C., and 110 C. The cooled casting was perfectly clear, colorless, tack-free, and flexible. Samples of the casting were not dissolved in 24 hours by acetone, ethylene dichloride, toluene or ethanol. The casting was stiff but not brittle at C. and at 150 C. was soft and pliable but not tacky. Upon being heated at 150 C. for 40 minutes the casting cured further and became rigid.

Example In a similar manner to that described in Example 8 a mixture of equal weights of styrene and isopropylideneglyceryl acrylate was polymerized at 50% concentration in toluene with 0.2% of benzoyl peroxide. The resultant solution was clear and colorless and had a viscosity of 28 poises at 25 C. This solution gelled slowly at room temperature upon the addition of catalytic amounts of boron trifluoride.

While the above examples are drawn to the preparation and use of isopropylidene acrylate and methacrylate, because these are the preferred products of this invention, it is to be understood, however, that the processes of the examples are those which are successful for the preparation of the other monomers of the general formula CHa=OCOOCH,('lH-(JH:

o o 0 R1 R= described above, and for the preparation of polymers and copolymers thereof.

We claim: 1. A polymerizable ester represented by the general formula eH,=o-ooo-cH,-( 3H-( JH,

o o R1/ \R:

wherein R represents a member of the class consisting of a hydrogen atom and a methyl group and R and R, each represents a member of the class consisting of a hydrogen atom and alkyl, cycloalkyl and aryl radicals which contain one to twelve carbon atoms, the total number of carbon atoms in said alkyl, cycloalkyl and aryl radicals represented by R and R being from one to twelve.

2. A polymerizable ester represented by the formula CH:=COO O-CHzCH--(IJHI G16: C I

3. A polymerizable ester represented by the formula 5. A polymerizable ester represented by the formula 6. A polymerizable ester represented by the formula 7. A polymer of an ester of claim 1.

8. A polymer of the ester of claim 2.

9. A polymer of the ester of claim 3.

10. A polymer of the ester of claim 4.

11. A polymer of the ester of claim 5.

12. A polymer of the ester of claim 6.

13. A copolymer of an ester of claim 1 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C said ester being present to an extent of at least 1 14. A copolymer of the ester of claim 2 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C' said ester being present to an extent of at least 10%.

15. A copolymer of the ester of claim 3 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C said ester being present to an extent of at least 10%.

16. A copolymer of the ester of claim 4 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C said ester being present to an extent of at least 1 17. A copolymer of the ester of claim 5 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C said ester being present to an extent of at least 10%- 18. A copolymer of the ester of claim 6 and another copolymerizable monomeric compound which contains a vinylidene group, CH2=C said ester being present to an extent of at least 10%.

References Cited in the file of this patent UNITED STATES PATENTS Number 

1. A POLYMERIZABLE ESTER REPRESENTED BY THE GENERAL FORMULA 